Photographic film packet manufacture

ABSTRACT

IN PHOSOGRAPHIC FILM PACKET MANUFACTURING APPARATUS HAVING STATIONS OPERATING ON WEB PORTIONS, FIRST AND SECOND DETECTORS, DOWNSTREAM OF FIRST AND SECOND STATIONS, PROVIDING SIGNALS TO A MEMORY IN RESPONSE TO WEB PORTION CONDITIONS, AN ELEMENT RESPONDING TO SIGNALS FROM THE FIRST DETECTOR TO PREVENT OPERATION OF THE SECOND STATION, AND AN EJECTOR FOLLOWING THE SECOND DETECTOR AND RESPONSIVE TO SIGNALS FROM IT TO PREVENT WEB PORTIONS FROM REACHING A TERMINAL STATION.

June 7 D. H. BUSHEY PHOTOGRAPHIC FILM PACKET MANUFACTURE 2 Sheets-Sheet1 Filed March 3, 1969 June 1, BUSHEY PHOTOGRAPHIC FILM PACKETMANUFACTURE 2 Sheets-Sheet 2 Filed March 3, 1969 United States Patent3,581,371 PHOTOGRAPHIC FILM PACKET MANUFACTURE Donald H. Bushey,Shrewsbury, Mass., assignor to Polaroid Corporation, Cambridge, Mass.Filed Mar. 3, 1969, Ser. No. 803,734 Int. Cl. B2311 19/04 US. Cl. 29-20815 Claims ABSTRACT OF THE DISCLOSURE This invention relates to themanufacture of photo graphic film packets.

The primary object of the invention is to minimize the loss of usefulpacket components on an automatic assembly line that is subject tostringent quality control.

The invention features, in apparatus for the manufacture of photographicfilm packets which has stations through which pass web portions and atwhich are respectively carried out in sequence various operations,including first and second stations for respectively depositing firstand second packet components on the web portions, and a terminal stationfor receiving finished packets, a first detector located downstream ofthe first station and being responsive to the absence of the firstcomponent on a web portion to provide a signal, at least one seconddetector located adjacent the path of the Web portions and responsive toa condition at the portions to provide a signal, a memory responsive tothe signals, an element responsive to the memory to prevent thedepositing of the second component on web portions which caused asignal, and an ejector located between the terminal station and thesecond station and responsive to the memory to prevent web portions forwhich the second detector provided a signal from reaching the terminalstation. In preferred embodiments the ejector is located downstream ofthe last station at which components are deposited on the web portions,so that web portions prevented from reaching the terminal station arepackets complete except for the existence of the condition, the firstdetector is located immediately downstream of the first station, thesecond detector is located downstream of the last station at whichcomponents are deposited on the web portions, the first detector isresponsive to the absence of a component which cannot be eifectivelyadded to the packet after it leaves the apparatus, and the seconddetector is downstream of the first detector and is responsive to acondition which can be effectively corrected after the packet leaves theapparatus to make the packet commercially useful, the second stationincludes a fluid operated mechanism having a fluid supply line and theelement is a valve in the line; there is included at least one rotatableslotted spider wheel for receiving finished packets in slots in oneposition and rotating to another position, and a member for transferringthe packets from the slots at the other position to the terminalstation, in which the ejector includes a movable arm responsive to thememory located at an intermediate position for ejecting packets forwhich the second detector provided a signal; there is also included asecond ejector located between the first and second detector andresponsive to the memory to prevent web portions for which the firstdetector provided a signal from reaching the second detector, the secondejector including a gate movable between a first position allowing thepassage of web portions and a second position interrupting the passageof web portions for which the first detector provided a signal; there isalso included a station having a member for turning alternate packets180, a second element responsive to the memory to prevent alternationwith respect to the next previous packet of any packet for which thefirst or second detector provided a signal, first and second cam wheelshaving effective operating portions out of phase with each other, firstand second rollers mounted for contact with the cam wheels and offsetfrom each other and respectively associated with the wheels so that onlyone roller may contact its corresponding cam wheel at a time, linkageconnected between the member and the rollers so that the packets areturned when one of said rollers is in contact with the effectiveoperating portion of its corresponding cam wheel, the second elementcausing the roller in contact with its corresponding cam wheel to moveaway from the wheel and causing the other roller formerly free tocontact its corresponding cam wheel.

Other objects, features, and advantages will appear from the followingdescription of a preferred embodiment of the invention, taken togetherwith the attached drawings thereof, in which:

FIG. 1 is a perspective view, partially broken away, of a photographicfilm packet of the type made by apparatus embodying the invention;

FIG. 2 is a fragmentary, partially schematic isometric View of portionsof apparatus embodying the invention;

FIG. 3 is an enlarged fragmentary perspective view of a portion of theapparatus of FIG. 2;

FIG. 4 is a fragmentary perspective view of another portion thereof; and

FIG. 5 is a fragmentary side view of another portion thereof.

Photographic film packet 10 (FIG. 1) includes, in part, outer walls 12and 13 of opaque paper, metal foil pod 18 for holding film processingchemicals, and a negative 20. Clip 21 is attached to one end of thepacket.

Packet 10 is assembled by apparatus shown in part in FIGS. 2-5.Continuous web 25, which eventually forms walls 12 and 13, is moved by amain drive (not shown) intermittently in packet-length incrementsthrough a sequence of stations at which it is folded and cut andreceives various components of the packets. A memory system 30 isprovided, consisting of a magnetic core memory stage 32 corresponding toeach station, and a clock 34 synchronized with the web drive foradvancing the signals in system 30 one stage for each packet-lengthadvance of web 25.

At negative detector station 40, downstream of the station 38 at whichthe web receives negatives 20, a feeler 60 is carried at the end ofvertically reciprocating arm 62 the other end of which controls theposition of the core of a linear variable diiferential transformer 64(LVDT). The output of the LVDT is applied to relay 66 which in turncontrols the position of switch 68 in the +12 volt line 70 to memorystage 32a. Upon each packet-length advance of the web arm 62 lowers tocause feeler 60 to lightly contact negative 20 or, if the negative ismissing, web 25.

At pod applicator station 42 vacuum chuck 72, carried by pivotal arm 74,picks up one pod 18 from tray 76 upon each packet-length advance of theweb, and positions the pod on the web for lamination thereto bylaminator 78. The vacuum supply to chuck 72 through line 80 includesvalve 82 operated by solenoid 83 the coil of which is wired to memorystage 3212 by wire 84.

At first packet ejection station 44, downstream of the station (notshown) at which the web is severed into individual packet lengths,driven pinch rollers 86 are provided just upstream of gate 87 pivotallymounted on shaft 88 (FIG. 3). Lever 89 is mounted at one end of shaft 88and is pivoted at its free end to piston 90 of air cylinder 91 connectedto a source of air pressure through line 92. Solenoid 93 operates valve94 in line 92, the solenoid including a coil wired to memory stage 320through Wires 95. A conveyor 96 below gate 87 extends to chute 97.

At pod detector station 46 a proximity head 102, sensitive to the metalfoil of pod 18, is positioned under the path of the packets. The outputof the head 102 is applied to relay 104 which in turn controls theposition of switch 106 in the +12. volt line 108 to memory unit 32d.

At packet alternator station 48 shaft 110 (FIGS. 1, 4) has at its top avacuum head 112 connected via the shaft interior to vacuum chamber 114,and carries gear 116 mating with a segment gear 118 which oscillatesaround pivot 120 in response to reciprocation of shaft 122 connected tothe main drive. Chamber .114 is connected at its bottom by a ball andsocket joint 124 to angle bracket 126 which carries on its verticalportion 128 an air cylinder 130. Bracket 126, pivotally mounted on shaft13-2, has a bias spring 134 between one end of horizontal portion 136and adjacent housing 138, and, at the junction of portions 128 and 136,links 140 and 142 fixed to pin 144 and offset from each other andrespectively carrying rollers 146 and 148. A central link 150 isattached at one end to pin 144 between links 140 and 142, and at theother end to the piston of air cylinder 130. Two parallel cam wheels 152and 154 are mounted respectively adjacent rollers 146 and 148 on shaft156, which is rotatable in synchronization with the main drive. Wheels152, .154 have low portions 152:; and 154a, respectively, 180 out ofphase. Because links 140 and 142 are offset from each other, only one ofrollers 1 46, 148 may be in contact with its corresponding cam wheel ata time. Solenoids 158 and 160 (FIG. 1), having coils wired to memoryunit 322, control air valves 159, 161, respectively, in air pressurelines 1 63, 165, which are connected to opposite ends of air cylinder130.

At station 50, a chain conveyor 170 (FIG. with lugs 171 is located justupstream of three spider wheels 172, each of which has slots 173 forreceiving packets from conveyor 170, the spider wheels being rotatablymounted on a shaft 174. Levers 175 are mounted between adjacent wheels172 each on a bracket 176 pivotable about pivot 177 and connectedthrough linkage 178 to the piston of air cylinder 179. Air valve 180(FIG. 1) in air pressure line 181 to air cylinder 179 is responsive tosolenoid 182 whose coil is wired to memory unit 32 Pinch rollers 190 aremounted downstream of wheels 172 and lead to reject chute 194. Aconveyor 196 for complete packets lies below the spider wheels. Arms 198are mounted between adjacent wheels 172 just above conveyor 196.

In operation, at station 40 the absence of a negative will cause arm 62to descend more than usual so that the signal from the LVDT will closeswitch 68 in relay 66, whereby a signal is transmitted to memory stage32a over line 70.

At station 42, pod 18 is deposited on the web unless a signalcorresponding to the absence of a negative on that portion of the webappears in memory stage 32b, such signal having originated in stage 32aand advanced through memory under the control of clock 34. In that case,the signal in stage 32b causes activation of solenoid 83 to open valve82, breaking the vacuum at chuck 72 so that a pod is not deposited onthe web.

At station 44, the then completely assembled packets are moved over gate87 by pinch rollers 86 unless a transmitted signal appears in memorystage 32c indicating the absence of a negative in the packet. In thatcase, solenoid 93 is energized by memory stage 32c, activating valve 94in air pressure line 92 so that air cylinder 91 causes gate 87 to open,allowing the packet to fall to conveyor 96 for 4 passage to chute 97.Such rejected packets are not salvageable. However, the memory feedbackto station 42 has ensured that packets rejected at station 44 do notinclude pods, thereby minimizing component loss.

If, as packets move over proximity head 102, the head senses the absenceof a pod, switch 106 in relay 104 is closed and a signal is transmittedto memory unit 32d.

At station 48 shaft rises for every other packet in response to motionof bracket 126 determined by the action of cam wheels 152, 154 on theirassociated rollers 146, 1 48, lifts the packet with vacuum head 112, andturns it 180, unless a rejects signal (originating either in stage 32aor $20!, the corresponding packet having been ejected in the formercase) is present in memory stage 32e indicating the absence of a pod. Inthat case, solenoids .158 and are energized by the memory, reversing thestates of air valves 159 and 161 in air pressure lines 163 and so thatair cylinder 130 reverses the position of its piston, pivoting link 150and pin 144 so that the roller following its cam wheel moves away fromthe wheel and the roller formerly free moves down to contact its camwheel. Since the cam wheels are out of phase, this will change thesequence of operation of shaft 110 by one packet length so that when theimperfect packet is later removed, the remaining packets will :be inalternation.

At station 50 packets are passed to slots 173 in spider wheels 172 byconveyor 170, the wheels rotate, and packets are pushed out of slots 173by arm 198 to fall on conveyor 196 which carries them to a suitablereceptacle (not shown), all unless a signal is present in memory unit 32In that case solenoid 182 will activate air valve 180 in air pressureline 181 so that air cylinder 179 will cause levers 175 to move fromtheir rest position (shown solid) to a position (shown dotted) at whichthey cause the packet to enter rollers which will carry the packet tochute 194.

Packets recovered from chute 194 are salvageable, since the missing podcan be effectively added manually.

Other embodiments will occur to those skilled in the art and are withinthe following claims.

What is claimed is:

1. In apparatus for the manufacture of photographic film packets, saidapparatus having stations through which pass Web portions and at whichare respectively carried out in sequence various operations pertainingto said manufacture, said apparatus including first and second stationsfor respectively depositing first and second packet components on saidweb portions, and a terminal station for receiving finished packets,

a first detector located downstream of said first station and beingresponsive to the absence on a web portion of said first component toprovide a signal,

at least one second detector located adjacent the path of said webportions and being responsive to a condition at said portions to providea signal,

a memory responsive to said signals,

an element responsive to said memory to prevent the said depositing ofsaid second component at said second station on web portions in responseto which said first detector provided a said signal, and

an ejector located between said terminal station and said second stationand responsive to said memory to prevent web portions for which saidsecond detector provided a said signal from reaching said terminalstation.

2. The apparatus of claim 1 in which said ejector is located downstreamof the last station at which components are deposited on said webportions, so that web portions prevented from reaching said terminalstation are packets complete except for the existence of said condition.

'3. The apparatus of claim 1 in which said first detector is locatedimmediately downstream of said first station.

4. The apparatus of claim 1 in which said second detector is locateddownstream of the last station at which components are deposited on saidweb portions.

5. The apparatus of claim 1 in which said first detector is responsiveto the absence of a component which cannot be effectively added to thepacket after it leaves said apparatus, and said second detector isdownstream of said first detector and is responsive to a condition whichcan be effectively corrected after the packet leaves said apparatus tomake said packet commercially useful.

6. The apparatus of claim 1 including at least one rotatable slottedspider wheel for receiving finished packets in slots in one position androtating to another position, and a member for transferring said packetsfrom said slots at said other position to said terminal station, inwhich said ejector includes a movable arm responsive to said memorylocated at a position intermediate said spider wheel positions forejecting packets for which said second detector provided a said signal.

7. The apparatus of claim 1 in which said element is directly associatedwith said second station to prevent normal functioning of apparatusthereat.

8. The apparatus of claim 7 in which said second station includes afluid operated mechanism having a fluid supply line and said element isa valve in said fluid supply line.

9. The apparatus of claim 1 including a second ejector locateddownstream of said first detector and upstream of said second detectorand responsive to said memory to prevent web portions for which saidfirst detector provided a said signal from reaching said seconddetector.

10. The apparatus of claim 9 in which said second ejector includes agate responsive to said memory, said gate movable between a firstposition allowing the passage of web portions and a second positioninterrupting the passage of web portions for which said first detectorprovided a signal.

11. The apparatus of claim 1 including a station at which there isperformed a sequence of different operations respectively on successivepackets, and a second element directly associated with said station,said second element being responsive to said memory to cause temporaryinterruption of said sequence upon receipt of a said signal provided bysaid second detector.

12. The apparatus of claim 11 in which said second element is alsoresponsive to a said signal provided by said first detector to causetemporary interruption of said sequence upon receipt of said signal.

13. The apparatus of claim 11 including a member for turning alternatepackets 180 at said last mentioned station and in which said secondelement is responsive to said memory to prevent alternation with respectto the next previous packet of any packet for which said second detectorprovided a said signal.

14. The appartaus of claim 13 including first and second cam wheelshaving effective operating portions out of phase with each other,

first and second rollers mounted for contact with said cam wheels andoffset from each other and respectively associated with said wheels sothat only one roller may contact its corresponding cam wheel at a time,

linkage connected between said member and said rollers so that saidpackets are turned when one of said 6 rollers is in contact with thesaid effective operating portion of its corresponding cam wheel,

said second element preventing alternation with respect to the nextprevious packet of any packet for which said second detector provided asaid signal by causing the roller in contact with its corresponding camwheel to move away from said wheel and causing the other of said rollersformerly free to contact its corresponding cam wheel.

15. In apparatus for the manufacture of photographic film packets, saidapparatus having stations through which pass web portions and at whichare respectively carried out in sequence various operations pertainingto said manufacture, said apparatus including first and second stationsfor respectively depositing first and second packet components on saidweb portions, in which said first component, if not deposited at saidfirst station, cannot be effectively added to the packet after it leavessaid ap paratus and said second component, if not deposited at saidsecond station, causes a condition which can be effectively correctedafter the packet leaves said apparatus to make said packet commerciallyuseful, and a terminal station for receiving finished packets,

a first detector located immediately downstream of said first stationand being responsive to the absence on a web portion of said firstcomponent to provide a signal,

at least one second detector located downstream of said first detector,downstream of the last station at which components are deposited on saidweb portions, and adjacent the path of said web portions and responsiveto said condition at said portions to provide a signal,

a memory responsive to said signals,

an element directly associated with said second station to prevent thesaid depositing of said second component at said second station on webportions in response to which said first detector provided a saidsignal,

a station at which there. is performed a sequence of differentoperations respectively on successive packets, and a second elementdirectly associated with said station, said second element beingresponsive to said memory to cause temporary interruption of saidsequence upon receipt of a said signal provided by said second detector,

a first ejector located downstream of said second detector and upstreamof said terminal station and responsive to said memory to prevent webportions for which said second detector provided a signal from reachingsaid terminal station, and

a second ejector located downstream of said first detector and upstreamof said second detector and responsive to said memory to prevent webportions for which said first detector provided a said signal fromreaching said second detector.

References Cited UNITED STATES PATENTS 3,003,229 10/1961 Powell 29-208JAMES M. MEISTER, Primary Examiner

